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Ha, yes safe to assume that. Safety is not on. I think it might be a bent plunger rod as the plunger seems to be binding somewhere

Yeah, I recently picked up my 1st emag and that was one of the things that many people stressed, take the sear rod out before you remove the rail. If it is a bent plunger, I think they can be fixed but I am not certain.

The plungers would naturally bend a bit through the cycling process. The best way to check for a binding plunger is to remove the valve from the gun, point the barrel end of the gun straight forward (so gravity is working to pull the plunger down) push down on the back end of the sear (part that contacts the on/off valve) and then let go and the sear should fall down and the back end of the sear should be all the way up. If it doesn't the plunger is binding in the solenoid and bending the clevis rod a bit will get it back in alignment and the solenoid won't have to work as hard to pull it down. Solenoids do go bad, but very rarely. I think I replaced maybe one or two in my time teching E-Mags...

The plungers would naturally bend a bit through the cycling process. The best way to check for a binding plunger is to remove the valve from the gun, point the barrel end of the gun straight forward (so gravity is working to pull the plunger down) push down on the back end of the sear (part that contacts the on/off valve) and then let go and the sear should fall down and the back end of the sear should be all the way up. If it doesn't the plunger is binding in the solenoid and bending the clevis rod a bit will get it back in alignment and the solenoid won't have to work as hard to pull it down. Solenoids do go bad, but very rarely. I think I replaced maybe one or two in my time teching E-Mags...

Thanks Black. Seem to be up and running now - was breaking paint last weekend so have to figure that out but at least I'm cycling!